Roof flashing strip and method of production

ABSTRACT

A roof flashing strip is formed by extruding or injection molding a suitable material of either polymer or metallic material. The roof flashing strip is formed as an elongated member which then can be cut to any suitable length. The roof flashing strip includes a backing plate having a plurality of legs projecting laterally outwardly therefrom and normal thereto. The legs are inclined with respect to a horizontal plane and vertically axially displaced such that there is a gap therebetween, with portion of adjacent legs overlying and/or underlying one another. The gap enables the emplacement of a shingle thereinto.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of co-pending U.S. application Ser. No. 10/519,759, filed Dec. 30, 2004, which claims the benefit of U.S. Provisional Application No. 60/393,396, filed Jul. 2, 2002 for Roof Flashing Strip and Method of Production, the entire disclosures of which is hereby incorporated by reference.

BACKGROUND OF THE INVENTION I. Field of the Invention

The present invention pertains to roofing flashing strips for waterproofing roofs. More particularly, the present invention pertains to a roof flashing system for waterproofing roofs.

In U.S. Pat. No. 5,946,862 there is disclosed a roof flashing strip and method of production wherein a plurality of individual metal flashing cards are assembled into a linear array to facilitate the installation of roof shingles or the like. According to the patent, the individual flashing cards, which are made of a suitable metal, such as aluminum, tin or the like are assembled together wherein partially overlapping cards are adhered or affixed to one another. An adhesive is used to bond one card to another or they are otherwise secured together with staples, tape or the like. It is to be appreciated that one of the difficulties is the manufacturing of the strip from individual cards. It is labor intensive to adhere a plurality of individual flashing cards together including depositing the bonding material thereonto in serial fashion.

SUMMARY OF THE INVENTION

In accordance with the present invention there is provided a roof flashing strip and a method of manufacture therefor which, generally, comprises an injection-molded or extruded elongated flashing strip. The strip is formed from a suitable material in a die or in a suitable mold. Preferably, the flashing strip is extruded in a suitable die under requisite conditions. The strip is formed from a suitable polymer. It may be formed from a plastic material such as polyvinylchloride (PVC), high density polyethylene, polyvinylacetate, or the like. These polymers are suitable for extrusion or injection molding. The strip may also be formed from an elastomeric material such as rubber.

Other suitable extrudable materials for forming the flashing strip include aluminum, brass, copper, lead, and the like, as well as other water impervious materials.

In extruding or injection molding the flashing strip, it is formed as a substantially elongated body member of an extended length, such as from about 6 to about 10 feet. This strip can, then, be cut to desired lengths.

The flashing strip made in accordance herewith, generally, comprises a backing member having a plurality of legs projecting laterally outwardly therefrom and substantially normal thereto. Each of the legs is angularly inclined by an angle θ with respect to a horizontal plane. The legs are configured in such manner that a portion thereof overlies an adjacent leg with a gap therebetween.

The gaps enable the insertion thereinto of a roofing shingle or the like.

The flashing material hereof can be used at the base of any vertical wall, such as a chimney, side wall, or the like.

There is provided a roof flashing system, such as for use with a vertical wall, such as a chimney, which comprises a flashing strip and a base strip. The roof flashing system is used when at least two adjacent walls of a vertical wall extend upwardly from the roof, and at least one wall-to-roof junction extends in a direction that is substantially parallel to the pitch of the roof, and at least one wall-to-roof junction extends in a direction that is substantially normal to the pitch of the roof. The flashing strip is placed along the junction that extends parallel to the pitch of the roof, while the base strip is placed along the junction that extends normal to the pitch of the roof. The roof flashing system provides for waterproofing all seams between the roof and walls.

The base strip generally comprises a backing member having a top strip and a bottom strip, both of which extend laterally. The top strip and bottom strip extend substantially parallel to each other, and are spaced such that a roofing shingle may be positioned between the top strip and the bottom strip.

For a more complete understanding of the present invention, reference is made to the following detailed description and accompanying drawing. In the drawing, like reference characters refer to like parts throughout the several views in which:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevation view of a flashing strip in accordance with the present invention;

FIG. 2 is a cross sectional view taken along line 2-2 of FIG. 1 and showing a shingle assembled thereto;

FIG. 3 is a side elevation view showing a base strip in accordance with the present invention;

FIG. 4 is a cross-sectional view taken along line 4-4 of FIG. 3; and

FIG. 5 is a perspective view showing the installation of a roof flashing system including the flashing strip and the base strip hereof against a chimney wall.

FIG. 6 is a perspective view of a roof flashing system showing the roof flashing strips connected end-to-end.

FIG. 7 is a side view of a mating clip for use in securing flashing strips together.

FIG. 8 is a perspective view showing the installation of a roof flashing system against adjoining walls.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Now, and with reference to FIG. 1, there is shown a flashing strip 10 according to the present invention.

The flashing strip 10 comprises an elongated member 16 of any desired length. In use, preferably, the member 16 has a length ranging from about 6 feet to about 10 feet.

The strip 10 has a backing wall or plate or backing surface 14. Projecting laterally outwardly from and substantially normal to the surface 14 of the member 16 are a plurality of substantially parallel legs 18, 18′, 18″, etc. Each of the legs 18, 18′, 18″, etc. is angularly disposed by an angle θ with respect to a horizontal plane 17 in serial array. Generally, the angle θ will range from about 1° to about 5°. Thus, the legs are vertically displaced from and angularly inclined with respect to a horizontal plane.

As shown in FIG. 1, each of the legs 18, 18′, etc., has a first lateral edge 20 and a second opposed lateral edge 22. Each leg is “rising” along the extent thereof from the first edge 20 to the second edge 22 by the angle θ.

Each of the legs 18, 18′, 18″, etc., has a predetermined length such that a portion thereof underlies an adjacent leg. In other words, a portion of each leg 18, 18′, etc., proximate the first edge 20 underlies a portion of an adjacent leg proximate its second edge 22, as shown. Thus, there is a gap 24 created or provided between overlying leg portions. As is discussed hereinafter and shown in FIG. 2, this gap 24 enables a roofing shingle or tile 30 to be disposed within the gap 24 for securement of the shingle or tile to an appropriate surface, such as a roof 27 or the like.

It should be noted that in the practice of the present invention, the gap 24 may be of any size and that the dimensions defined herewithin are preferred but are not intended to be limitative.

In accordance herewith, the flashing strip 10 is manufactured from a die by extruding or injection molding a suitable material in a suitable mold, depending on the method of manufacture employed. Preferably, the flashing strip is injection-molded in a suitable mold under requisite conditions as dictated by the materials selected for forming. The flashing strip 10 may also be manufactured by adhering each of the legs 18, 18′, 18″, etc. onto the backing plate 14 using adhesives which are well-known to one of ordinary skill in the art. The type of adhesive used is dependent upon the type of material from which the backing plate 14 and legs 18, 18′, 18″, etc. are formed.

Suitable injection-molding materials for use herein include, for example, polyvinylchloride (PVC), high density polyethylene (HDPE), polyvinylacetate (PVA), polyurethane, rubber, and the like. The selection of material is dictated solely by its ability to be molded and withstand climatic conditions. Thus, not only polymers such as plastics or elastomers, but moldable metals may be used as well. In the practice of the present invention it is preferred to use a polymer, and even more preferable to use an elastomer such as rubber.

It is critical hereto that the metal or polymeric material selected for use herein have sufficient durability to withstand weathering for an extended period of time and at the same time have a sufficient degree of pliability, if necessary, to enable a tile or shingle to be inserted in the gap 24 and at the same time be capable of being severed to required or desired lengths along the length of the strip.

It is to be appreciated that by providing elongated strips of polymeric flashing, it is possible to cut the flashing strip to any desired length or to place strips in adjacent or side-by-side relationships, as is discussed in further detail below.

It is contemplated that the extent of overlap between the consecutive legs 18, 18′, 18″, etc. will vary between 1″ and 7″. It is generally understood by one of ordinary skill in the art that the extent of overlap between the legs will be dictated by the size of shingles used for each particular application. In manufacturing the flashing strip, the degree of overlap may vary depending on the need to accommodate various sizes of shingles. If, for example, a roof is to be manufactured from small shingles, the legs 18, 18′, 18″, etc., would overlap from about 5″ to about 7″. In this way, more shingles may be placed upon the roof, which would be necessary due to the small size of the shingles. On the other hand, if the shingles are exceptionally large on the magnitude of about 18″, then the flashing strip would have the individual legs 18, 18′, 18″, etc., overlapping between 1″ and 4″. An exemplary, and preferred, size of shingles is 12″. According to this size of shingle, 7″ of the shingle is to be inserted within the gap 24 between the legs 18, 18′ and 5″ of the shingle is exposed and overlaying the next successive leg 18″.

In use, the backing plate 14 of the flashing strip 10 is abutted against a surface, such as a chimney 40, an exterior wall or the like. The strip may be bonded to the surface via suitable bonding material such as tar, adhesive or the like to prevent any moisture from seeping in between the surface of the plate and the wall or chimney to which it is secured. It can also be secured with a nail, staple, or the like.

It is apparent that the flashing strip of the present invention provides several advantages over currently available flashing cards and flashing strips in that it is a continuous one piece product which may be cut to size; prevents water damage to a home by providing an environmental sealing between each of adjacent leg and is extremely stable.

In a further aspect of the present invention, and as shown in FIGS. 2-5, the flashing strip is used in a roof flashing system which comprises a flashing strip 10 and a base strip 36. The roof flashing system is used when at least two adjacent walls extend upwardly from the roof, and at least one wall-to-roof junction extends in a direction that is substantially parallel to the pitch of the roof, and at least one wall-to-roof junction extends in a direction that is substantially normal to the pitch of the roof. The flashing strip 10 is placed along the junction that extends parallel to the pitch of the roof, while the base strip 36 is placed along the junction that extends normal to the pitch of the roof.

As shown in FIGS. 2 and 3, the base strip 36 generally comprises a backing wall or backing surface 14. Projecting laterally outwardly from and at an angle α to the surface 14 is a top strip 38 and a bottom strip 42 which extend along the base strip 36. The top strip 38 and bottom strip 42 extend in a direction substantially parallel to each other, and are spaced such that a shingle or tile may be positioned between the top strip 38 and the bottom strip 42.

As shown in FIG. 2 and in use, a shingle 30 is slidably seated in the gap 24 of the strip 10 with its bottom surface 32 seated atop the upper surface of the leg 18 and an edge 34 thereof abutting the plate 14 of the base strip 38.

In yet another aspect of the invention as shown in FIGS. 6 and 7, a roof flashing system 100 is provided which comprises a plurality of roof flashing strips secured to each other end-to-end. Each roof flashing strip 10, 10′, 10″, etc., has a first end 44 and an opposed second end 46. The plurality of roof flashing strips are arranged end-to-end such that the second end 46 of a first roof flashing strip 10 overlies the first end 44′ of a second roof flashing strip 10′, the second end 46′ of the second roof flashing strip 10′ overlies the first end 44″ of a third roof flashing strip 10″, and so on. The backing plate 14 of each adjoining pair of roof flashing strips 10, 10′, etc. are adjacent each other.

A mating clip 48, 48′, 48″, etc. is provided for securing each pair of juxtaposed backing plates together. Each of the mating clips 48, 48′, 48″, etc. is generally U-shaped and has a pair of opposed walls 50, 50′ which connect at a union 52, such as shown in FIG. 7. In use, one of the mating clips is positioned over each pair of juxtaposed backing plates 14 such that the opposed walls 50,50′ of each of the mating clips 48 are frictionally-fit over the juxtaposed backing plates 14, wherein the adjacent roof flashing strips 10, 10′, 10 etc. are secured in position with respect to each other.

The mating clips 48, 48′, etc. are formed from extrudable or injection-moldable polymers which are well-known to one of ordinary skill in the art, such as PVC, HDPE, PVA, polyurethane, rubber and the like.

As shown in FIG. 6, each of the backing plates may have a spacer tab 52 secured thereon to dictate the amount of overlap between adjacent roof flashing strips, such as shown in FIG. 6. In a preferred application, the spacer tab 52 allows for 3″ of overlap. The spacer tab 52 is substantially rectangular in shape and formed from the same material as the flashing strip 10. The spacer tab 52 may be adhered to the flashing strip by means which are well known in the art, such as by adhesives. Preferably, the spacer tab 52 is integrally molded onto the flashing strip 10. In use, adjacent roof flashing strips 10, 10′ are overlapped, and the end of the overlaying roof flashing strip 10 is abutted against the spacer tab 52 of the underlying strip. As such, it is seen that the spacer tab 52 is used to standardize the amount of overlap between adjoining roof flashing strips 10, 10′.

It is also appreciated that the roof flashing strips 10 are provided in both left and right hand pieces, and that the particular roofing application will dictate which (or both) orientations are to be used. As such, it is to be appreciated that the present invention is directed toward both left and right hand orientations of the roof flashing strips 10.

It is to be understood that the specific geometric configuration of the roof flashing strip 10, including the length of the legs 18, the amount of overlap of the legs 18, and the size of the gap 24 between the legs 18 is determined by the size, shape, and thickness of the shingle used for any particular application. Therefore, it is understood that the present invention may be dimensioned for use with any type of shingle or roofing material.

It is apparent from the preceding that there has been described herein a flashing strip, a roof flashing system, and a method of manufacture therefor that is easy to use and reduces the time necessary to manufacture same over prior systems. 

1. A roof flashing system comprising: a plurality of roof flashing strips, each roof flashing strip having a first end and an opposed second end and being formed from an elongated member having a backing plate and a succession of substantially parallel legs projecting laterally outwardly therefrom, the legs being inclined with respect to a horizontal plane at an angle θ of at least one degree and each leg having opposed first and second edge portions, such that the succession of legs are positioned so that the first edge of a first leg overlaps the second edge of a second leg, and the first edge of the second leg overlaps the second edge of a third leg, the plurality of roof flashing strips being arranged end-to-end such that the second end of a first roof flashing strip overlying the first end of a second roof flashing strip, and the backing plate of the first and second roof flashing strips are adjacent each other; and at least one mating clip for securing at least two juxtaposed backing plates together, the at least one mating clip being generally U-shaped and having a pair of opposed walls which connect at a union, one of the mating clips being positioned over each pair of juxtaposed backing plates such that the opposed walls of each of the mating clips are frictionally-fit over the juxtaposed backing plates, such that the adjacent roof flashing strips are secured in position with respect to each other.
 2. The roof flashing system of claim 1 wherein the angle θ ranges from about one degree to about five degrees.
 3. The roof flashing system of claim 1 wherein each of the backing plates has a spacer tab secured thereon, the spacer tab determining the amount of overlap between adjacent roof flashing strips.
 4. The roof flashing system of claim 1 wherein the plurality of roof flashing strips and the at least one mating clip are rubber flashing strips and a rubber mating clip.
 5. The roof flashing system of claim 1 wherein a gap is defined between the overlying portions of the legs such that a shingle may be disposed therebetween. 